2012-2013 Polaris Sportsman 400 H.O. / 500 2012–2013 Service Manual (P/N 9923792)
Polaris Models Covered & Key Technical Specifications
Models: 2012–2013 Sportsman 400 H.O., 2012–2013 Sportsman 500 H.O., 2012–2013 Forest 500, 2012–2013 Sportsman Touring 500 H.O., 2012–2013 Sportsman Forest Tractor 500 EFI
Sub-models / Variants: South Edition, EFI Tractor, Int’l
Trade Names: Sportsman, Forest
Model Years: 2012–2013
Serial Numbers: 2012-2013 VIN patterns starting with 4XAMH
Technical Data:
- Engine displacement: 455 cc (400 H.O.) and 498 cc (500 H.O. / EFI)
- Engine type: Fuji single-cylinder, 4-stroke, liquid-cooled
- Transmission: In-Line H/L/N/R/P (400/500), Drumshift (Touring/Forest)
- Drive system: 2WD/4WD shaft drive
- Fuel type: 87 Octane minimum (89 oxygenated)
- Alternator output: 260 watt @ 3000 RPM (Carb models), 350 watt @ 5000 RPM (EFI model)
- Spark plug gap: 0.035 in (0.9 mm)
Polaris Manual Features & Content Preview
- Original OEM publication 9923792 (copyright 2012 Polaris Sales Inc.) serving as the primary factory reference for the entire 2012–2013 production build.
- Covers the Polaris Sportsman 400 H.O. and 500 series, including Touring, Forest, and EFI Tractor variants.
- Spans 438 pages containing detailed engine exploded views, wiring schematics, and complete torque specification tables.
- Documents both carbureted and EFI fuel systems across all 400 and 500 platform configurations.
Contents Overview
Shop technicians and mechanics need fast access to reliable data. This OEM manual delivers precise technical documentation for chassis diagnostics, engine maintenance, and electrical system troubleshooting. You'll find initial sections breaking down VIN decoding, vehicle identification, and factory paint codes. Next comes a comprehensive outline of periodic maintenance charts and approved lubricant listings.
Since ATV maintenance involves high-pressure components and heavy lifting, always review the manufacturer's foundational safety protocols outlined in the opening chapters before starting diagnostic work.
The core technical content dives into cylinder head disassembly, valvetrain inspection, crankshaft runout, and transmission repair sequences. Need to trace a short? The electrical references include alternator output ratings, circuit breaker specifications, and critical sensor values. Drivetrain chapters break down gear ratios, front gearcase maintenance, and altitude-specific clutching setups.
Specification Previews
Accurate specs prevent costly comebacks. The manual provides hard data for the Fuji 498cc platform, listing a compression ratio of 10.2:1 alongside the exact service limit for compression pressure. You get verified torque values for all major engine fasteners—from cylinder head bolts to crankshaft nuts—listed in both ft-lbs and Nm.
- Intake valve clearance for the 500 H.O. sits at 0.006” (0.15 mm).
- Radiator cap relief pressure is set at 13 PSI (89.6 kPa) for both carbureted and EFI variants.
- Alternator output for the fuel-injected Forest Tractor 500 EFI rates at 350 watts @ 5000 RPM.
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